Clock Spring Contour

Qualification Data as Required by ISO TS 24817

Test Report
For work undertaken by
Oxford Brookes University

Report No. JTRC/CS/01-2007

January 2007

Work undertaken for: Clock Spring Company, L.P.

621 Lockhaven Drive
Houston
Texas
777073 USA

To Order No.: SM82306-PH1

School of Technology
Joining Technology Research Centre
Oxford Brookes University
Wheatley Campus
Oxford
OX33 1HX

Tel: +44 (0) 1865 483504

Fax: +44 (0) 1865 484179
E-mail: jtrc@brookes.ac.uk
www.brookes.ac.uk/jtrc
Contents

Summary of Test Data 3

Measurement of tensile properties 4

Measurement of lap shear strengths 5

(short term and after 1000 hour exposure in water)

Measurement of fracture toughness parameter, LCL 6

Leak tests 6
Calculation of LCL 7

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Summary of Test Data
Material: Clock Spring Contour
Resin: CS600A/B
Fabric: Four layer, stitched glass fibre fabric

CLOCK SPRING CONTOUR ISO TS 24817 QUALIFICATION DATA

QUALIFICATION REQUIREMENT RESULT RESULT
Ply or layer thickness 2.1mm 0.0827 inch
Tensile modulus (circumferential) 11.0 GPa 1.60 x 106 psi
Tensile modulus (axial) 10.8 GPa 1.57 x 106 psi
Tensile Strain to failure (circumferential) 1.8 % 1.8%
Tensile Strain to failure (axial) 1.9 % 1.9%
Tensile Strength (circumferential) 147 MPa 21.3 ksi
Tensile Strength (axial) 149 MPa 21.6 ksi
Thermal expansion coefficient
15.7 x 10-6 C-1 8.7 x 10-6F-1
(circumferential)
Thermal expansion coefficient (axial) 15.7 x 10-6 C-1 8.7 x 10-6F-1
Poissons ratio (circumferential) 0.29 0.29
Poissons ratio (axial) 0.30 0.30
Shear Modulus (resin) 1.1 GPa 0.159 x 106 psi
Barcol/Shore Hardness 82.5 shore D 82.5 shore D
Glass Transition 99oC 210oF
Lap Shear Strength to Steel 10.0 MPa 1450 psi
Aged Lap Shear Strength
9.3 MPa 1349 psi
(1000 hours in 93 C water)

Fracture Toughness, LCL 149 Jm-2 0.851in lbf/in2

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Measurement of tensile properties

Cure Conditions Test Set-up

Date: 14/11/2006 Test Machine: Nene Univeral Tester
De-ionised Water: n/a Load Cell: 100kN
Temperature: 23 C Extensometer: LVDT (0.01 Resolution)
Humidity 60 % Gauge Length: 50mm
Period: 0 hours Test Speed: 2mm/min.
Test Date: 14/12/2006 End Tabs: GFRP Quad (3 ply - Tapered)

Specimen Length: 300mm

Specimen Width: 25mm
Specimen Thickness: 2-ply
Strain Guage: EA-06-060RZ-120
Gauge Length: 3mm
Gauge Factor: 2.06
Gauge Resistance: 120ohms
Data Logger: Spider8

Sample ID Width Thickness CSA Load to Failure Tensile Strength Tensile Modulus Poison's Strain to failure Mode of Failure
2 2
QUAD (mm) (mm) (mm ) (kN) (N/mm ) (kN/mm2) Ratio (%)
Q1-A 25.38 3.46 87.81 13.20 150.32 9.58 -0.25 Transverse within free length
Q1-B 24.89 3.66 91.10 13.25 145.45 11.20 -0.30 Transverse within free length
Q1-C 24.90 3.72 92.63 13.79 148.88 12.11 -0.33 End tab failure
Q1-D 24.98 3.63 90.68 12.92 142.48 11.21 2.161 End tab failure
Q1-E 24.99 3.65 91.21 13.09 143.51 10.09 1.693 End tab failure
Q1-F 24.95 3.41 85.08 12.75 149.86 11.55 1.672 End tab failure
Mean 25.02 3.59 89.75 13.17 146.75 10.96 -0.29 1.84 2-direction
SD 0.18 0.12 2.78 0.36 3.39 0.94 0.04 0.28

Sample ID Width Thickness CSA2 Load to Failure Tensile Strength

2
Tensile Modulus Poison's Strain to failure Mode of Failure
QUAD (mm) (mm) (mm ) (kN) (N/mm ) (kN/mm2) Ratio (%)
Q2-A 24.99 4.24 105.96 15.72 148.36 10.59 -0.30 End tab failure
Q2-B 24.96 4.06 101.34 15.39 151.87 8.66 -0.28 End tab failure
Q2-C 24.91 4.0 99.14 14.86 149.89 11.27 -0.31 End tab failure
Q2-D 25.02 4.1 101.33 15.63 154.25 13.76 2.009 End tab failure
Q2-E 24.97 4.1 102.63 15.15 147.62 10.45 1.934 End tab failure
Q2-F 24.98 4.00 99.92 13.94 139.51 9.81 1.789 End tab failure
Mean 24.97 4.07 101.72 15.12 148.58 10.76 -0.30 1.91 1-direction
SD 0.04 0.09 2.41 0.66 5.06 1.71 0.01 0.11

Sample ID Stress Longitudinal Transverse Poison's Mean Poison's Tensile Modulus

(N/mm2) micro-strain micro-strain Ratio Ratio (N/mm2)
Q1B 20.04 1726 -520 -0.3013 11609
40.07 3715 -1110 -0.2988 -0.30 10786 11197 11.20
Q1C 20.13 1657 -541 -0.3265 12148
40.06 3319 -1093 -0.3293 -0.33 -0.29 12070 12109 12.11
Q1A 20.01 2095 -506 -0.2415 9553
40.03 4170 -1060 -0.2542 -0.25 9599 9576 9.58
Q2A 20.03 1889 -577 -0.3055 10603
35.02 3312 -998 -0.3013 -0.30 10574 10589 10.59
Q2B 20.17 2375 -667 -0.2808 8491
40.14 4547 -1314 -0.2890 -0.28 -0.30 8827 8659 8.66
Q2C 20.01 1750 -538 -0.3074 11436
40.03 3603 -1126 -0.3125 -0.31 11109 11273 11.27

Samples Q1 Tested in Circumferential Direction

Samples Q2 Tested in Axial Direction

TENSILE TEST RESULTS IN GENERAL ACCORDANCE WITH ASTM D3039

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Measurement of lap shear strengths
(short term and after 1000 hour exposure in water)

Plate 1 - DRY Date made: 07/11/2006

Conditions: DRY
Cure (both plates): 46 hrs 24C
Test temps: 24C / 43%rh
Period: 24 hours
Test date: 09/11/2006

Sample ID Width Overlap CSA Load to Failure Shear Strength

2 2
Plate 1 (mm) (mm) (mm ) (kN) (N/mm )
L1-B 25.41 12.3 313 3.19 10.20
L2-C 25.36 12.4 314 Broke before test
L4-D 25.45 12.5 318 Broke before test
L3-E 25.66 12.6 323 1.17 3.63
L5-F 25.34 12.2 309 4.08 13.20
L6-G 25.29 12.3 311 3.97 12.78
mean 25.42 12.38 315 3.10 9.95
SD 0.13 0.15 5 1.35 4.42

Plate 2 -WET Date made: 07/11/2006

De-ionised water: 5.2S
Temperature: 93C
Humidity: Immersed in water
Period: 1000 hours
Test date: 20/12/2006

Sample ID Width Overlap CSA Load to Failure Shear Strength

2 2
Plate 2 (mm) (mm) (mm ) (kN) (N/mm )
L1-B 25.37 12.2 309.01 2.88 9.31
L2-C 25.44 12.0 306.30 3.15 10.29
L4-D 25.76 12.7 326.38 2.88 8.81
L3-E 0.00 Broke before test
L5-F 25.36 12.5 316.75 2.74 8.65
L6-G 0.00 Broke before test
mean 25.48 12.35 210 2.91 9.26
SD 0.19 0.29 163 0.17 0.74

LAP SHEAR TEST RESULTS IN GENERAL ACCORDANCE WITH BS EN 1465 - 1995

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Measurement of fracture toughness parameter, LCL

Leak tests
Laminate thickness: 6.7mm (5-ply)
Pressure fitting: 1/4'' bsp
Cure: 7 days at ambient (23C2, 50% RH 5)
Surface preparation: Grit blast with P60 Alumina
Surface roughness: Medium (50m)
Test temperature: 22.4C / 44% rh
Test rate: ~200 bar per minute (closed-loop control)
Test date: 31/10/2006

Sample ID Surface Roughness Hole Diameter Failure Pressure

(m) (mm) (bar)
LT 1 50 25 72
LT 2 48 25 56
LT 3 52 25 71
mean 50 25 66
sd 2 0 9

Sample ID Surface Roughness Hole Diameter Failure Pressure

(m) (mm) (bar)
LT 4 60 20 78
LT 5 48 20 68
LT 6 56 20 73
mean 55 20 73
sd 6 0 5

Sample ID Surface Roughness Hole Diameter Failure Pressure

(m) (mm) (bar)
LT 7 46 15 80
LT 8 59 15 117
LT 9 50 15 127
mean 52 15 108
sd 7 0 25

LEAKAGE TEST RESULTS IN ACCORDANCE WITH ISO TS 24817 ANNEX D

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Calculation of LCL

Test data Material constants

Test No. Defect diameter (mm) Pressure (bar) Repair thickness (mm) Combined Tensile modulus, E ac (GPa) 10.9
LT1 25 72 6.7 Poissons ratio, 0.29
LT2 25 56 6.7 Shear modulus, G (GPa) 1.1
LT3 25 71 6.7
LT4 20 78 6.7 Repair data
LT5 20 68 6.7 Average thickness (mm) 6.70
LT6 20 73 6.7
LT7 15 80 6.7 Design data
LT8 15 117 6.7 Service factor 1
LT9 15 127 6.7

(J/m )
2 2
Defect diameter (mm) Repair thickness (mm) Ai for hole Pressure (bar) Pressure (N/m ) Pi-Ppred
25 6.70 4.35E+05 72 7.20E+06 8.80E+05 274.13
25 6.70 4.35E+05 56 5.60E+06 -7.20E+05 165.83
25 6.70 4.35E+05 71 7.10E+06 7.80E+05 266.57
20 6.70 5.47E+05 78 7.80E+06 -1.48E+05 203.44
20 6.70 5.47E+05 68 6.80E+06 -1.15E+06 154.62
20 6.70 5.47E+05 73 7.30E+06 -6.48E+05 178.20
15 6.70 7.22E+05 80 8.00E+06 -2.50E+06 122.68
15 6.70 7.22E+05 117 1.17E+07 1.20E+06 262.41
15 6.70 7.22E+05 127 1.27E+07 2.20E+06 309.18
Number of data point 9 Mean
Sum Ai 5.11E+06 5.68E+05
Sum Pi 7.42E+07 8.24E+06
2
Sum Ai 3.02949E+12
Sum AiPi 4.40314E+13
(J/m2) - mean 211.245

2
2.31E+12
97.5% student t value 2.685
LCL (J/m2) 148.544

Fracture toughness of repair, mean (J/m )

2
211.2
Fracture toughness of repair, LCL (J/m2) 148.5

CALCULATION OF USING ANALYSIS IN ISO TS 24817

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